Bumper Clevis Shackle Mounts?

Bumper Clevis Shackle Mounts?

Postby Lumpy [OP] » May 27th 2015, 5:24pm

Hey CargoCrawler -

I'm looking at some pics in your album from your (old) winch mount (before the ARB bumper). Did you weld/laminate two half inch thick shackle mounts together to form a 1" thick mount or ???

How did you bore the holes for the clevis pins?


Thanks - Lump
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Re: Bumper Clevis Shackle Mounts?

Postby 97cargocrawler » May 27th 2015, 10:39pm

Indeed I did. Bought 4 mounts from Ballistic Fab and did this:

Drilled holes in each separately (3/4" I think) with drill press:

Image

Beveled the inner edges for more weld surface area:

Image

Image

Welded up and ground smooth:

Image

I prolly ran the drill through again to match the holes. It's impossible to weld the split in the hole area so you may want to paint the insides of the halves before welding. I didn't worry about it. You could bevel the insides there too and squirt your choice of goop in there after its welded to prevent water ingress.

Welded onto the carrier:

Image

Image
Image
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Re: Bumper Clevis Shackle Mounts?

Postby Lumpy [OP] » May 27th 2015, 11:42pm

Groovy, thanks.

All the trade offs.

Drilling through very thick steel.
Cutting very thick steel.
Welding very thick steel.

.375 I can work with pretty well but it's right at the edge. .250 I'm getting pretty good at. I can only get my cheapo Craftsman china drill press down to 650 RPM. I can get my big cheapo HarborFreight china hand held slow speed impact/drill down a lot slower but, of course, it's hand held. And then there's huge drill bits/hole saws.

I'm looking for 1.000 thick with 1.000 hole. I'd like to simply build the subframe adaptor "horns" out of something like .500 and include the tabs sticking out the front of the sheet metal bumper. Use that as the guide/mount for the thinner bumper metal AND for the skeleton for the winch plate. Then weld lam on an additional couple slabs of .500 at the tabs, sort of like you did. Goal is to have one, thick piece of steel (per side) coming forward from the subframe to beyond the front of the bumper.

Not much on that thin subframe. I'd enjoy seeing how you reinforced that area. I looked at all the pics in your jackb. But can't really see how you mounted things to the van.


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Re: Bumper Clevis Shackle Mounts?

Postby Old Barney » May 28th 2015, 12:05am

Looks like a "C" clamp to me I don't think that is the best Idea though to hold it on the sub fame. I would rather have couple more "C" clamps
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Re: Bumper Clevis Shackle Mounts?

Postby 97cargocrawler » May 28th 2015, 6:49am

Yep, just one Chinese C clamp from HF holding it on there :D Good enough right?

The topside of the carrier bolts to the arms sticking forward that are welded to the OLV bumper relocation brackets. Then those arms coming back from the carrier bolt to the upright brackets on the middle frame crossmember thingy.

Image

Image

It was very compact and solid. I spent a really long time trying to get it right. Now it's scrap metal.

Image

Image

And then the brush guard went on top of all that...etc.

My new bumper mounts similarly:

Image

Image

You can almost see the bottom support bars in this pic. The bottom bars keep the top section of the bumper from teetering into the hood during impact and also bring the factory crush zone into play where the airbag sensor lives.

Image
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Re: Bumper Clevis Shackle Mounts?

Postby Lumpy [OP] » May 28th 2015, 7:14am

97cargocrawler wrote:
... middle frame crossmember thingy.

Image



"Middle frame crossmember thingy"...You built that piece? How does IT mount to the subframe horns?


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Re: Bumper Clevis Shackle Mounts?

Postby 97cargocrawler » May 28th 2015, 7:22am

Lumpy wrote:"Middle frame crossmember thingy"...You built that piece? How does IT mount to the subframe horns?
Lump


Nope, that's a Gen 2/3 van thing I guess. Not sure what year that started but I know the older vans don't have it. It's barely welded to the frame rails, purposely. Behind it are two rectangular boxes with slits cut in them that extend back to the real crossmember between the control arms. It's a designated crush zone. The airbag sensor is mounted to it.

This junk:

Image

Image
Image
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Re: Bumper Clevis Shackle Mounts?

Postby Lumpy [OP] » May 28th 2015, 7:27am

Fascinating stuff. Thanks a lot.


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